TWI677387B - Methods and apparatuses for producing metallic powder material - Google Patents

Abstract

A method of manufacturing a metal powder material includes: supplying a feed material to a melting hearth; and melting the feed material on the melting hearth with a first heat source to provide a molten material having a desired chemical composition. At least a portion of the molten material is transferred directly or indirectly from the melting hearth to the atomizing hearth in which the second heat source is used to heat the melting material. At least a portion of the molten material is transferred from the atomizing hearth to the atomizing device in a molten state, and the atomizing device forms a droplet spray from the molten material. At least a portion of the droplet spray is solidified to provide a metal powder material.

Description

Method and device for manufacturing metal powder material

The invention relates to a method and an apparatus for manufacturing a metal powder material. In particular, certain non-limiting aspects of the present invention relate to a method for making a metal powder material using a device comprising: a melting hearth adapted to receive a feed material; and an atomizing hearth, It is positioned to receive at least a portion of the molten material from the melting hearth. In certain non-limiting embodiments of the method of the present invention, the method includes: passing at least a portion of the molten material in a molten state from the atomizing hearth to an atomizing device, which atomizing device may include an atomizing nozzle. The present invention is also directed to a metal powder material and article manufactured by the method and apparatus of the present invention.

Conventionally, gas atomization and hot equalization (also called "HIP") are used to form metal objects from metal powder materials. In these processes, a melt having the desired chemical composition is prepared and the molten composition is passed through an atomizing device in which a gas jet disperses the molten composition into quenched droplets. These quenched droplets form a loose powder. Metal powder materials can be hot-pressed to form metal objects.

Another conventional method for making metal objects is nucleation casting. Nucleation casting uses gas atomization to make a spray of semi-liquid droplets deposited into a mold. A common line is that some part of the droplet spray ( ie , excessive spray) can accumulate on the top surface of the mold. Similar to nucleation casting in several respects, spray forming is a customary technique in which metal objects are formed by spraying semi-liquid droplets without using a mold.

In conventional nucleation casting, spray forming, and gas atomization / HIP sequences, the solidified material that has been previously melted into the desired chemical composition is re-melted to provide the molten material to the atomization device. In one example, the solidified material with the desired chemical composition is thermomechanically processed into a wire and then remelted for atomization. In another example, a cold wall induction furnace is used to melt and homogenize previously solidified material before the atomization process. When the material solidifies before remelting and atomizing, the material may be contaminated, such as during thermomechanical processing and processing. Contaminants in the solid material can become entrained in the molten metal stream provided to the atomizing device. Remelting the solidified material for atomization can also limit the ability to control process parameters, such as molten metal superheat and flow rate, which may need to be controlled to ensure consistent atomization. In addition, the use of solidified materials for remelting and atomization can increase the costs associated with the manufacture of atomized metal powder.

The present invention is directed, in part, to methods and devices that address certain limitations of conventional methods of making metal powder materials. A non-limiting aspect of the present invention is directed to a method for manufacturing a metal powder material, the method comprising: supplying a feed material to a melting hearth; and melting the feed material in the melting hearth with a first heat source Thus, a molten material having a desired composition is manufactured; at least a portion of the molten material is transferred to an atomizing hearth; a second heat source is used to heat the molten material in the atomizing hearth; at least a portion of the molten material is The molten state is transferred directly or indirectly from the atomizing hearth to the atomizing device; and the atomizing device is used to form a droplet spray of the molten material. At least a portion of the droplet spray is solidified to provide a metal powder material. In certain non-limiting embodiments of the method, at least a portion of the molten material is continuously transferred to the atomizing device. In certain non-limiting embodiments of the method, the molten material is transferred from the melting hearth to the atomizing hearth through at least one additional hearth.

Another non-limiting aspect of the present invention is directed to an apparatus for manufacturing a metal powder material. The device includes: a melting hearth adapted to receive a feed material; a first heat source adapted to melt the feed materials in the melting hearth and produce a molten material having a desired composition; an atomizing furnace A bed arranged to receive at least a portion of the molten material directly or indirectly from the melting hearth; a second heat source adapted to heat the molten material in the atomizing hearth; an atomizing device adapted to Forming a droplet spray of the molten material; a transfer unit coupled to the atomizing hearth and the atomizing device; and a collector adapted to receive the droplet spray from the atomizing device. The transfer unit is adapted to transfer molten material from the atomizing hearth to the atomizing device in a molten state.

200‧‧‧ device

200’‧‧‧ device

210‧‧‧melt chamber

220‧‧‧ Melting hearth

230‧‧‧The first heat source

240‧‧‧Feed material

250‧‧‧Feed chute

260‧‧‧ molten material

270‧‧‧Atomizing hearth

280‧‧‧The first condensation shell

290‧‧‧Second Condensate

292‧‧‧ Extra hearth

300‧‧‧Second heat source

310‧‧‧Atomization device

320‧‧‧Transfer Unit

330‧‧‧ Entrance

340‧‧‧Export

350‧‧‧Conductive coil

360‧‧‧melt container

370‧‧‧Access

380‧‧‧Conductive coil / coil

382‧‧‧Induction Guide

384‧‧‧ pouring groove

386‧‧‧Segmented induction mould

388‧‧‧Cold induction guide

390‧‧‧ additional heat source

400‧‧‧ Collector

The features and advantages of the methods and alloy objects described herein can be better understood by referring to the drawings, in which: Figure 1 is a non-limiting implementation of a method for manufacturing a metal powder material according to the present invention Figure 2 is a schematic cross-sectional side view illustrating a non-limiting embodiment of a device for manufacturing a metal powder material according to the present invention; Figure 3 is a schematic plan view of the device of Figure 1; Figure 5 is a schematic plan view of another non-limiting embodiment of the inventive device for manufacturing a metal powder material; Figure 5 is an enlarged partial cross-sectional side view of the device of Figure 1; and Figure 6 is a diagrammatic illustration of manufacturing a metal powder material according to the invention A schematic cross-sectional side view of another non-limiting embodiment of the device.

It should be understood that the invention is not limited in its application to the embodiments illustrated in the drawings set forth above. The reader will immediately understand the foregoing and other details after considering the following detailed description of certain non-limiting embodiments of methods and devices according to the present invention. The reader may also immediately understand some of these additional details after using the methods and devices described herein.

Except in the operating examples or where otherwise indicated, and also in the description of the non-limiting examples and within the scope of patent applications, the quantity or characteristics of all expressed ingredients and products, processing conditions, and the like should be all numbers It is understood to be modified in all instances by the term "about". Therefore, unless the contrary is indicated, any numerical parameter set forth in the following description and the scope of the accompanying patent application is an approximation that can vary depending on the desired characteristics sought to be obtained in the method and apparatus according to the present invention. At a minimum, and not an attempt to limit the application of the principle of equivalence to the scope of patent applications, each numerical parameter should be interpreted based on the number of valid digits reported and by applying ordinary rounding techniques.

The present invention is directed, in part, to methods and devices that address some of the limitations of conventional methods of making metal powder materials. Referring to FIG. 1, a non-limiting embodiment of a method of manufacturing a metal powder material is illustrated. The method includes: supplying a feed material to a melting hearth (block 100); melting a feed material in the melting hearth with a first heat source, thereby manufacturing a molten material having a desired chemical composition (block 110); and melting the At least a portion of the material is transferred directly or indirectly to the atomizing hearth (block 120); the second heat source is used to heat the molten material in the atomizing hearth (block 130); at least a portion of the molten material is melted from the atomizing furnace in a molten state The bed is passed to an atomizing device (block 140); and a droplet spray of molten material is formed using the atomizing device (block 150). At least a portion of the droplet spray is solidified to provide a metal powder material having the desired composition.

2 to 3, a illustrated non-limiting embodiment of an apparatus 200 for manufacturing a metal powder material includes a melt chamber 210 and a melting hearth 220 and a first heat source 230 positioned in the melt chamber 210. The melt chamber 210 is configured to maintain the atmosphere therein. The atmosphere may have a pressure below atmospheric pressure, above atmospheric pressure, or at atmospheric pressure. According to certain non-limiting embodiments, the gas atmosphere in the melt chamber 210 may be chemically inert with respect to the material heated in the melt chamber 210. According to certain non-limiting embodiments, the gas atmosphere in the melt chamber 210 may be helium, argon, a blend of helium and argon, or another inert gas or gas mixture 组合。 The compound. According to other non-limiting embodiments, other gases or gas blends are in the atmosphere in the melt chamber 210 if the gases or gas blends have not unacceptably contaminated the molten material in the melt chamber 210.

The melting hearth 220 is adapted to receive the feed material 240. According to certain non-limiting embodiments, the feed material 240 is a pure raw material. According to other non-limiting embodiments, the feed material 240 includes or consists of the following: scrap, return, recycled material, and / or master alloy. According to certain non-limiting embodiments, the feed material 240 comprises particulate material. According to other non-limiting embodiments, the feed material 240 comprises or consists of a material in the form of a fabricated or previously fused electrode (for example, a previously fused material such as a cylinder or rectangular prism). And other materials. In any case, in the method according to the present invention, the chemical composition of the molten material manufactured in the melting hearth 220 is adjusted to the desired composition by selectively adding a feed material to the melting hearth 210.

According to certain non-limiting embodiments, the feed material 240 mainly comprises a titanium material. According to certain non-limiting embodiments, the feed material 240 is selected to provide a molten material having a chemical composition of one of the following: commercial pure titanium, titanium alloys ( e.g. , Ti-6Al-4V alloy, which It has the composition specified in UNS R56400) and titanium aluminum alloy ( for example , Ti-48Al-2Nb-2Cr alloy). According to another non-limiting embodiment, the feed material 240 is selected to provide a molten material that includes about 4% vanadium, about 6% aluminum, and the remainder titanium and impurities by weight. (Unless otherwise indicated, all percentages herein are weight percentages.) According to yet another non-limiting embodiment, the feed material 240 is selected to provide a molten material having a chemical composition of one of the following: : Commercial pure nickel, nickel alloy ( for example , alloy 718, which has the composition specified in UNS N07718), commercial pure zirconium, zirconium alloy ( for example , Zr 704 alloy, which has the composition specified in UNS R60704), Commercially pure niobium, niobium alloys ( e.g. , ATI Nb1Zr ^TM alloys (type 3 and type 4) having a composition specified in UNS R04261), commercial pure tantalum, tantalum alloys ( e.g. , tantalum-10% tungsten alloy, which having a composition), commercially pure tungsten and tungsten alloy (e.g., tungsten alloy 90-7-3) UNS 20255 as stipulated. It will be understood that the methods and apparatus described herein are not limited to the manufacture of materials with the aforementioned chemical compositions. Instead, the starting materials can be selected to provide a molten composition having the desired chemical composition and other desired properties. The molten material is atomized in the method and apparatus herein, thereby providing a metal powder material having a chemical composition of the molten material atomized into a powder.

According to some non-limiting embodiments, the feed material 240 is fed into the melting hearth 220 via a feed mechanism, such as, for example, a feed chute 250. According to certain non-limiting embodiments, the feeding mechanism includes at least one of a vibrating feeder, a chute, and a pusher. In other non-limiting embodiments, the feed mechanism includes any other mechanism that can suitably introduce the feed material 240 onto the melting hearth 220.

According to certain non-limiting embodiments, the first heat source 230 associated with the melting hearth 220 includes at least one heating device selected from the group consisting of a plasma torch, an electron beam generator, another heating device that generates electrons, Laser and arc devices and induction coils. In one example, the first heat source 230 is adapted to use a plasma torch to melt the feed material 240 in the melting hearth 220 to thereby manufacture a molten material 260 having a desired chemical composition. The first heat source 230 is adapted and positioned to heat the feed material in the melting hearth 220 to a temperature at least as large as the melting temperature (liquidus) of the feed material 240 and to maintain their materials in a molten state at Melting hearth 220. In certain non-limiting embodiments, the first heat source 230 heats the molten material formed in the melting hearth 220 to at least partially refine the molten material. According to certain non-limiting embodiments, the first heat source 230 may be positioned at about 100 mm to about 250 mm above the upper surface of the melting hearth 220. According to other non-limiting embodiments, the first heat source 230 includes a first plasma torch positioned at a height relative to a top surface of the molten material in the melting hearth 220 such that the first plasma torch The edges of the feathers of the torch-made thermoplasma suitably heat the material. According to certain non-limiting embodiments, the power level of the first heat source 230, its position relative to the melting hearth 220, and other parameters are selected to heat the molten material 260 in the melting hearth 220 to a liquid phase containing the material line A temperature range up to about 500 ° C above the melting point of the material. According to other embodiments, the power level, location and other parameters of the first heat source 230 are optimized to overheat the material in the melting hearth 220 to about 50 ° C above the liquidus line containing the material until the liquid of the material A temperature range of about 300 ° C above the phase line. According to other embodiments, the power level, position, and other parameters of the first heat source 230 are optimized to overheat the material to a temperature that exceeds any suitable degree of the liquidus line of the material, as long as the first heat source 230 does not evaporate the material And / or the chemical properties of the molten material may be changed in an undesired manner.

According to certain non-limiting embodiments, the atomizing hearth 270 is positioned to directly or indirectly receive at least a portion of the molten material 260 from the melting hearth 220. Once melted and suitably heated, the molten material 260 in the melting hearth 220 can be drained from the melting hearth 220 and passed directly or indirectly ( eg, through at least one additional hearth) to the atomizing hearth 270. The atomizing hearth 270 collects the molten material 260 directly or indirectly from the atomizing hearth 270, and can hold the molten material when the molten material 260 is transferred from the atomizing hearth 270 and passed to the atomizing nozzle of the atomizing device 310. At least a portion of 260, as explained further below. In this regard, the atomizing hearth 270 functions as a "surge buffer" for the molten material 260 that regulates the flow of the molten material 260 to the atomizing device 310. According to certain non-limiting embodiments, the atomizing hearth 270 is disposed in the melt chamber 210 together with the melting hearth 220. According to other embodiments, the atomizing hearth 270 is not in a single chamber with the melting hearth 220 and may instead be located in another chamber, such as an adjoining chamber.

According to various non-limiting embodiments, at least one additional hearth is disposed between the melting hearth 220 and the atomizing hearth 270, and the molten material is transferred from the melting hearth 260, passes through the at least one additional hearth, and enters the atomizing furnace. Bed 270. This configuration is described herein as involving the passage of molten material indirectly from the melting hearth to the atomizing hearth.

According to certain non-limiting embodiments and referring to FIG. 5, both the melting hearth 220 and the atomizing hearth 270 are water-cooled copper hearths. If present, one or more additional hearths present in various non-limiting embodiments may also be water-cooled copper hearths. According to other non-limiting implementations For example, at least one of the melting hearth 220, the atomizing hearth 270, and one or more additional hearths (if present) are constructed of any other suitable material and component and cooled or otherwise adapted to prevent the furnace The bed melts as the material is heated. According to certain non-limiting embodiments, a portion of the molten material 260 contacts the cooled wall of the melting hearth 220 and can be solidified to form a first condensation shell 280 that prevents the remaining portion of the melting material 260 from contacting the melting hearth 220, thereby isolating the wall of the melting hearth 220 from the molten material 260. Further, in some embodiments, a portion of the molten material 260 contacts the cooled wall of the atomizing hearth 270 as the molten material 260 flows from the melting hearth 220 into the atomizing hearth 270 and may solidify on the wall to A second condensation shell 290 is formed, which prevents the remainder of the molten material 260 from contacting the wall of the atomizing hearth 270, thereby isolating the wall of the atomizing hearth 270 from the melting material 260. In certain non-limiting embodiments, one or more additional hearths, if present, can be operated in a similar manner to prevent undesired contact of the molten material with the hearth wall.

Depending on the use requirements or preferences of a particular method or device 200, the material can be refined and / or homogenized while heating the material on the melting hearth 220, the atomizing hearth 270, and one or more additional hearths (if present) . For example, in refining molten material, high-density solid inclusions and other solid contaminants in the molten material can sink to the bottom of the molten material in a specific hearth and become entrained on the hearth wall in. Certain low-density solid inclusions or other solid contaminants can float on the surface of the molten material in a particular hearth and evaporate by an associated heat source. Other low-density solid inclusions or other solid contaminants can be suspended with equilibrium buoyancy and slightly below the surface of the molten material, and dissolved in the molten material in the hearth. In this manner, the molten material 260 is refined because solid inclusions and other solid contaminants are removed from or dissolved in the molten material 260.

Referring also to FIG. 4, according to the illustrated non-limiting embodiment, at least one additional hearth 292 is positioned between the melting hearth 220 and the atomizing hearth 270. At least a portion of the molten material 260 on the melting hearth 220 is passed through one or more additional hearths 292 before being transferred into the atomizing hearth 270. In certain non-limiting embodiments, the additional hearth 292 may be used in the following At least one of the operations: refining the molten material 260 and homogenizing the molten material 260. "Refining" and "homogenization" are technical terms and will be easily understood by those skilled in the art of metal powder material manufacturing. Generally speaking, in connection with hearth components, refining may involve removing, dissolving, or capturing impurities or undesired components from the molten material in the hearth and preventing the impurities or undesired components from proceeding downstream. Homogenization may involve mixing or blending the molten material so that the material has a more uniform composition. According to certain non-limiting embodiments, one or more additional hearths 292 are positioned in series with the melting hearth 220 and the atomizing hearth 270 to provide a substantially straight line or a path selected from a generally zigzag path, a generally L-shaped path, and a substantially A C-shaped path is an alternative shaped flow path of the molten material 260. According to certain non-limiting embodiments, an additional heat source (not shown) is associated with one or more of the additional hearths 292. According to certain non-limiting embodiments, the additional heat source includes one or more heating devices selected from the group consisting of a plasma torch, an electron beam generator, another heating device that generates electrons, a laser, an arc device, and an induction coil .

According to certain non-limiting embodiments, the second heat source 300 is adapted to heat the molten material 260 in the atomizing hearth 270. According to certain non-limiting embodiments, the second heat source 300 includes at least one heat source selected from the group consisting of a plasma torch, an electron gun, an electron generating heating device, a laser, an arc, and an induction coil. The second heat source 300 is positioned to heat the top surface of the molten material in the atomizing hearth 270 to a temperature at least as great as the melting temperature (liquidus) of the material. According to certain non-limiting embodiments, the second heat source 300 may be positioned at about 100 mm to about 250 mm above the atomizing hearth 270. According to certain non-limiting embodiments, the second heat source 300 includes a plasma torch positioned at a height relative to the top surface of the molten material on the atomizing hearth 270 such that the edges of the plume of the thermoplasma The material is suitably heated. According to certain non-limiting embodiments, the power level of the second heat source 300, its position relative to the atomizing hearth 270, and other parameters are selected to overheat the material on the atomizing hearth 270 to the liquidus line of the material A temperature range above about 50 ° C to about 400 ° C above the liquidus of the material. According to other embodiments, the power level, position, and other parameters of the second heat source 300 are optimized to overheat the material on the atomizing hearth 270 to about the liquidus line of the material. A temperature range from 100 ° C to about 200 ° C above the liquidus of the material. According to other embodiments, the power level, location, and other parameters of the second heat source 300 are optimized to overheat the material to a temperature above any suitable degree of the liquidus, as long as the second heat source 300 does not vaporize the material and / or The chemical properties of the molten material may be changed in an undesired manner.

According to certain non-limiting embodiments, the atomizing device 310 includes an atomizing nozzle adapted to form a droplet spray of the molten material 260, and the transfer unit 320 is upstream of the atomizing device 310. For example, the transfer unit 320 may directly transfer the molten material to the atomizing nozzle. The transfer unit 320 is coupled to the atomizing hearth 270 and the atomizing device 310. The second heat source 300 is designed to keep the molten material 260 flowing into the transfer unit 320 in a molten state, and the transfer unit 320 is adapted to transfer at least a portion of the molten material 260 from the atomizing hearth 270 to the mist in a molten state.化 装置 310。 The device 310. Although only a combination of a single transfer unit and a single atomizing device is included in the illustrated device 200, it is contemplated that embodiments including multiple atomizing devices, such as multiple atomizing nozzles, may be advantageous. For example, in a device employing multiple transfer units 320 and one or more atomizing nozzles or other atomizing devices 310 downstream of the atomizing hearth 270, the process rate can be increased and material manufacturing costs can be reduced.

Referring to FIG. 5, according to the illustrated non-limiting embodiment, the transfer unit 320 is a cold induction guide (CIG). Figure 6 illustrates a device 200 'according to another non-limiting embodiment of the invention. The transfer unit 320 of the device 200 'includes an induction guide 382, which optionally includes a pouring groove 384 other than CIG 388 and a segmented induction mold 386. In the illustrated non-limiting embodiment of the device 200 ', an additional heat source 390 is associated with the pouring groove 384 and the segmented induction mold 386.

The transfer unit 320 maintains the purity of the molten material 260 manufactured in the melting hearth 220 and transferred from the atomizing hearth 270 to the atomizing device 310 by protecting the molten material 260 from the external atmosphere. The transfer unit may also be configured to protect the molten material from oxide contamination that may result from the use of conventional atomizing nozzles. The transfer unit 320 can also be used to measure the flow of the molten material 260 from the atomizing hearth 270 to the atomizing device 310, as explained further below. release. After considering this manual, a person of ordinary skill will be able to provide various possibilities of a transfer unit and associated equipment capable of controllingly transferring the molten material 260 (maintained in a molten state) between the atomizing hearth and the atomizing device. Alternative designs, as used in embodiments of the apparatus and method of the present invention. All such transfer unit designs that can be incorporated into the methods and devices of the present invention are encompassed within the present invention.

According to certain non-limiting embodiments, the transfer unit 320 includes an inlet 330 adjacent to the atomizing hearth 270 and an outlet 340 adjacent to the atomizing device 310, and one or more conductive coils 350 are positioned at the inlet 330. A current source (not shown) is selectively electrically connected to the conductive coil 350 to heat the molten material 260 and initiate flow of at least a portion of the molten material 260 to the atomizing device 310. According to certain non-limiting embodiments, the conductive coil 350 is adapted to heat the molten material 260 to a temperature within a range of the material's liquidus up to 500 ° C above the liquidus.

According to certain non-limiting embodiments, the transfer unit 320 includes a melt container 360 for receiving the melted material 260, and the transfer area of the transfer unit 320 is configured to include a melt container 360 configured to receive the melted material 260 from the melt container 360. Pathway 370. The wall of the passage 370 is delimited by several liquid-cooled metal segments. According to certain non-limiting embodiments, the transfer unit 320 includes one or more conductive coils 380 positioned at the outlet 340. The coil 380 is cooled by circulating a suitable coolant, such as water or another thermally conductive fluid, through a conduit associated with the outlet 340. A portion of the molten material 260 contacts the cooled wall of the passage 370 of the transfer unit 320 and may solidify to form a coagulation shell that isolates the wall from contact with the remaining portion of the molten material 260. The cooling of the hearth wall and the formation of the condensation shell ensure that the melt is not contaminated by the materials forming the inner wall of the transfer unit 320.

During the time that the molten material 260 is flowing from the melt container 360 of the transfer unit 320 through the passage 370, an electric current is transmitted through the conductive coil 380 with an intensity sufficient to inductively heat the molten material 260 and maintain the strength of the molten material 260 in a molten form. The coil 380 acts as an induction heating coil and adjustably heats the molten material 260 passed through the outlet 340 of the transfer unit 320. According to certain non-limiting embodiments, the conductive coil 380 is adapted to transfer molten material 260 is heated to a temperature ranging from 50 ° C above the liquidus of the material to 400 ° C above the liquidus. In other embodiments, the conductive coil 380 is adapted to heat the molten material 260 to a temperature within the range of the liquidus temperature of the material up to 500 ° C above the liquidus. According to certain other non-limiting embodiments, the conductive coil 380 is adapted to selectively prevent the passage of the molten material 260 to the atomizing device 310.

According to certain non-limiting embodiments, at least a portion of the molten material 260 is continuously transferred to the atomizing device 310. In these non-limiting embodiments, the molten material 260 flows continuously from the melting hearth 220 to the atomizing hearth 270, passes through the transfer unit 320, leaves the outlet 340 of the transfer unit 320, and is transferred to the atomizing device 310 . In certain non-limiting embodiments, the flow of molten material 260 to the atomizing hearth 270 may be discontinuous ( ie , have a start and stop). In various non-limiting embodiments, the molten material 260 flows from the melting hearth 220 through at least one additional hearth, and flows to the atomizing hearth 270, passes through the transfer unit 320, exits the exit 340 of the transfer unit 320, and Transfer to the atomizing device 310. According to certain non-limiting embodiments, the atomizing device 310 includes an atomizing nozzle including a plurality of plasma atomizing torches that converge at one point and form a spray of droplets of the molten material 260. According to other non-limiting embodiments, the atomizing nozzle includes three plasma torches that are equally distributed to define an angle of about 120 ° between each other. In these embodiments, each of the plasma torches may also be positioned to form an angle of 30 ° with respect to the axis of the atomizing nozzle. According to certain non-limiting embodiments, the atomizing device 310 includes an atomizing nozzle including a plasma jet generated by a DC gun operating in a power range of 20 kW to 40 kW. According to certain non-limiting embodiments, the atomizing device 310 includes an atomizing nozzle that forms at least one gas jet that disperses the molten material 260 to form a droplet spray.

The resulting droplet spray is directed into a collector 400. According to certain non-limiting embodiments, the position of the collector 400 relative to the atomizing nozzle or other atomizing device 310 is adjustable. The distance between the atomization point and the collector 400 can control the solid fraction in the material deposited in the collector 400. Therefore, when the material is deposited, the collector 400 may be adjusted relative to the atomizing nozzle or The position of the other atomizing device 310 is such that the distance between the surface of the collected material in the collector 400 and the atomizing nozzle or other atomizing device 310 is appropriately maintained. According to certain non-limiting embodiments, the collector 400 is selected from a chamber, a mold, and a rotating mandrel. For example, in certain non-limiting embodiments, when material is deposited into the collector 400, the collector 400 may be rotated to better ensure that droplets are evenly deposited over the surface of the collector 400.

Although the foregoing description of the device 200 refers to the melting hearth 220, the atomizing hearth 270, the atomizing device 310, the transfer unit 320, and the collector 400 as relatively discrete units or components of serially associated devices, it will be understood that The device 200 need not be constructed in another way. Rather than being constructed of discrete, disconnectable melting (and / or melting / refining) units, transfer units, atomizing units, and collector units, devices (such as device 200) according to the present invention may be incorporated to provide them The basic characteristics of each of them, but not the elements or areas that can be decomposed into discrete and individually operable devices or units. Therefore, references to melting hearths, atomizing hearths, atomizing devices, transfer units and collectors in the scope of the accompanying patent application should not be construed to mean that these different units can be used without loss of operability Disassociate from the claimed device.

In certain non-limiting embodiments, the various non-limiting embodiments of the method disclosed herein or the metal powder material manufactured by the various non-limiting embodiments of the device include an average particle of 10 microns to 150 microns size. In certain non-limiting embodiments, the various non-limiting embodiments of the method disclosed herein or the metal powder materials manufactured by the various non-limiting embodiments of the device have a particle size of 40 microns to 120 microns Distribution ( ie , the particle size of virtually all powder particles is in the range of 40 microns to 120 microns). Metal powder materials with a particle size distribution of 40 microns to 120 microns are particularly useful in electron beam additive manufacturing applications. In certain non-limiting embodiments, the various non-limiting embodiments of the method disclosed herein or the metal powder material manufactured by the various non-limiting embodiments of the device have a particle size of 15 to 45 microns Distribution ( ie , the particle size of virtually all powder particles is in the range of 15 microns to 45 microns). Metal powder materials with a particle size distribution of 15 to 45 microns are particularly useful in laser additive manufacturing applications. According to certain non-limiting embodiments, the metal powder material includes spherical particles. In certain other non-limiting embodiments, at least a portion of the metal powder material has other geometric forms including, but not limited to, flakes, chips, needles, and combinations thereof.

According to certain non-limiting embodiments, the metal powder material has a composition that cannot be easily manufactured by conventional ingot metallurgy ( eg , melting and casting techniques). That is, the methods that have been described herein may be able to make metal powder materials using compositions that are highly segregatable or have properties that prevent them from being cast by conventional ingot metallurgy. According to certain non-limiting embodiments, the boron content of the metal powder material is greater than 10 ppm based on the total powder material weight. In the melting and casting of conventional ingots, boron levels above 10 ppm can produce harmful borides. In contrast, various non-limiting embodiments of the methods set forth herein permit the manufacture of metal powder materials with boron content greater than 10 ppm without exhibiting unacceptable harmful phases or properties. This expands the possibilities of a composition of metal powder materials that can be manufactured.

Metal powder materials made according to the methods and devices of the present invention may have any composition suitably made using the methods and devices of the present invention. According to certain non-limiting embodiments, the metal powder material has a chemical composition of one of the following: commercial pure titanium, titanium alloys ( e.g. , Ti-6Al-4V alloys having a combination specified in UNS R56400 Materials) and titanium aluminum alloys ( for example , Ti-48Al-2Nb-2Cr alloy). According to another non-limiting embodiment, the metal powder material has a chemical composition material that includes about 4% vanadium, about 6% aluminum, and the remainder titanium and impurities by weight. (Unless otherwise indicated, all percentages herein are weight percentages.) According to yet another non-limiting embodiment, the metal powder material has a chemical composition of one of the following: commercial pure nickel, nickel alloys ( e.g. , alloy 718, having a composition of UNS N07718 as stipulated), commercially pure zirconium, zirconium alloy (e.g., Zr 704 alloy, having a composition UNS R60704 as stipulated), commercially pure niobium, niobium alloys (e.g., ATI Nb1Zr ^TM alloy (type 3 and type 4), which has the composition specified in UNS R04261, commercial pure tantalum, tantalum alloy ( e.g. , tantalum-10% tungsten alloy, which has the composition specified in UNS 20255 ), Commercial pure tungsten and tungsten alloys ( for example , 90-7-3 tungsten alloys). It will be understood that the methods and apparatus described herein are not limited to the manufacture of metal powder materials with the foregoing chemical compositions. Instead, the starting materials can be selected to provide a metal powder material having the desired chemical composition and other desired properties.

Metals ( e.g. , metals and metal alloys) made from metal powder materials made according to the method of the present invention and / or using the apparatus of the present invention can be made by means of hot equalization techniques for forming objects from metallurgical powders and other suitable conventional techniques. object. Those of ordinary skill will readily understand these other suitable technologies after considering the present invention.

Although the foregoing description has necessarily provided only a limited number of embodiments, those of ordinary skill in the relevant art will understand that methods and apparatus and other details of the examples that have been illustrated and illustrated herein can be made by those skilled in the art. Various changes, and all such modifications will remain within the principles and scope of the invention as expressed herein and within the scope of the accompanying patent applications. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed or incorporated herein, but is intended to cover modifications within the principles and scope of the invention as defined by the scope of the patent application. Those skilled in the art will also understand that changes can be made to the above embodiments without departing from the broad inventive concepts of the invention.

Claims (44)

A method for manufacturing a metal powder material, the method comprising: supplying a feed material to a melting hearth; melting the feed material in the melting hearth with a first heat source, thereby manufacturing a molten material; At least a portion is directly or indirectly transferred from the melting hearth to the atomizing hearth; a second heat source is used to heat the melting material in the atomizing hearth; at least a part of the melting material is from the atomizing hearth in a molten state Passed through the cold induction guide to the atomizing nozzle, wherein the cold induction guide includes an inlet adjacent to the atomizing hearth and an outlet adjacent to the atomizing nozzle, and wherein the conductive coil is positioned at the inlet and adjusted Heating the molten material to initiate transfer of the at least a portion of the molten material from the atomizing hearth to the atomizing nozzle; and using the atomizing nozzle to form a droplet spray of the molten material, followed by spraying the droplet At least a portion of it is solidified to provide a metal powder material. The method of claim 1, wherein the at least a portion of the molten material is passed from the melting hearth through the at least one additional hearth before entering the atomizing hearth. The method of claim 1, wherein the first heat source and the second heat source each independently include at least one of the following: a plasma torch, an electron beam generator, a heating device that generates electrons, a laser, and an arc device And induction coils. The method of claim 1, wherein before the molten material is transferred into the atomizing nozzle, at least one of the following operations is performed on the molten material: refining and homogenization. The method of claim 1, wherein the conductive coil is adapted to heat the molten material in a range from a liquidus of the material to 500 ° C above the liquidus. The method of claim 1, wherein the cold induction guide includes an inlet adjacent to the atomizing hearth and an outlet adjacent to the atomizing nozzle, and wherein the conductive coil is positioned at the outlet and is adapted to adjustably heat the Melt material. The method of claim 6, wherein the conductive coil is adapted to heat the molten material in a range from a liquidus of the material to 500 ° C above the liquidus. The method of claim 1, wherein the cold induction guide comprises an inlet adjacent to the atomizing hearth and an outlet adjacent to the atomizing nozzle, wherein a conductive coil is positioned at the outlet and adapted to stop the molten material to the The passage of the atomizing nozzle. The method of claim 1, wherein the atomizing nozzle comprises a plurality of plasma atomizing torches that form a plasma jet that converges at one point and sprays the droplets formed of the molten material. The method of claim 1, wherein the atomizing nozzle forms at least one gas jet that disperses the molten material into the droplet spray. The method of claim 1, wherein the at least a portion of the molten material is continuously transferred to the atomizing nozzle. The method of claim 1, wherein the composition of the metal powder material is selected from commercial pure titanium, titanium alloy, titanium aluminum alloy, commercial pure nickel, nickel alloy, commercial pure zirconium, zirconium alloy, commercial pure niobium, niobium alloy, Commercial pure tantalum, tantalum alloy, commercial pure tungsten and tungsten alloy. The method of claim 1, wherein the composition of the metal powder material comprises more than 10 ppm of boron. The method of claim 1, wherein the composition of the metal powder material comprises about 4% vanadium, about 6% aluminum by weight and the balance is titanium and impurities. The method of claim 1, wherein the average particle size of the metal powder material is in a range of 10 to 150 microns. The method of claim 1, wherein the metal powder material has a particle size distribution of 40 to 120 microns. The method of claim 1, wherein the metal powder material has a particle size distribution of 15 to 45 microns. A metal powder material manufactured by the method of claim 1, wherein the composition of the metal powder material includes about 4% of vanadium, about 6% of aluminum by weight, and the balance is titanium and impurities. The metal powder material of claim 18, wherein the composition of the metal powder material is selected from commercial pure titanium, titanium alloy, titanium aluminum alloy, commercial pure nickel, nickel alloy, commercial pure zirconium, zirconium alloy, commercial pure niobium, niobium Alloy, commercial pure tantalum, tantalum alloy, commercial pure tungsten and tungsten alloy. The metal powder material of claim 18, wherein the metal powder material has an average particle size of 10 to 150 microns. The metal powder material of claim 18, wherein the particle size distribution of the metal powder material is 40 micrometers to 120 micrometers. The metal powder material of claim 18, wherein the particle size distribution of the metal powder material is 15 micrometers to 45 micrometers. The metal powder material of claim 18, wherein the metal powder material includes boron greater than 10 ppm. An apparatus for manufacturing a metal powder material, the apparatus comprising: a melting hearth adapted to receive a feed material; a first heat source adapted to melt the feed material to provide a molten material; an atomizing hearth which Arranged to receive at least a portion of the molten material directly or indirectly from the melting hearth; a second heat source adapted to heat the molten material in the atomizing hearth; an atomizing nozzle adapted to cause droplets The spray is formed by the melting material; a transfer unit coupled to the atomizing hearth and the atomizing nozzle, wherein the transferring unit is adapted to transfer the molten material from the atomizing hearth to the atomizing nozzle in a molten state; And a collector, which is adapted to receive the droplet spray. The device of claim 24, further comprising at least one additional hearth between the melting hearth and the atomizing hearth and in communication with the melting hearth and the atomizing hearth. The apparatus of claim 25, wherein the melting hearth, the atomizing hearth, and the at least one additional hearth are positioned on a line. The device of claim 25, wherein the melting hearth, the atomizing hearth, and the at least one additional hearth are positioned in an offset configuration with a pattern selected from a sawtooth configuration, an L-shaped configuration, and a C-shaped configuration. The apparatus of claim 25, wherein at least one of the melting hearth, the atomizing hearth, and the at least one additional hearth is adapted to perform at least one of the following: refining the molten material and homogenizing the Melt material. The apparatus of claim 24, wherein the first heat source is associated with the melting hearth and the second heat source is associated with the atomizing hearth. The device of claim 29, wherein the first heat source and the second heat source each independently include at least one of a plasma torch, an electron beam generator, an electron generating heating device, a laser, an arc device, and an induction coil. The device of claim 25, wherein the additional heat source is associated with the at least one additional hearth, and wherein the additional heat source includes at least one of the following: a plasma torch, an electron beam generator, a heating device that generates electrons, Laser and arc devices and induction coils. The device of claim 24, wherein the transfer unit includes a cold induction guide. The device of claim 32, wherein the cold induction guide includes an inlet adjacent to the atomizing hearth and an outlet adjacent to the atomizing nozzle, and wherein a conductive coil is positioned at the inlet and adapted to heat the molten material to The at least a portion of the molten material is initially transferred to the atomizing nozzle. The device of claim 33, wherein the conductive coil is adapted to heat the molten material in a range from the liquidus of the material to 500 ° C above the liquidus. The device of claim 32, wherein the cold induction guide includes an inlet adjacent to the atomizing hearth and an outlet adjacent to the atomizing nozzle, and wherein the conductive coil is positioned at the outlet and is adapted to adjustably heat the Melt material. The device of claim 35, wherein the conductive coil is adapted to heat the molten material in a range from the liquidus of the material to 500 ° C above the liquidus. The device of claim 35, wherein the cold induction guide includes an inlet adjacent to the atomizing hearth and an outlet adjacent to the atomizing nozzle, and wherein the conductive coil is positioned at the outlet and adapted to stop the molten material to The atomizing nozzle passes. The device of claim 24, wherein the atomizing nozzle comprises a plurality of plasma atomizing torches that form a plasma jet of the droplet spray that converges at one point and forms the molten material. The device of claim 24, wherein the atomizing nozzle forms at least one gas jet that disperses the molten material into the droplet spray. The device of claim 24, wherein the position of the collector relative to the atomizing nozzle is adjustable. The device of claim 24, wherein the collector is selected from the group consisting of a chamber, a mold, and a rotating mandrel. A method for manufacturing a metal powder material, the method comprising: supplying a feed material to a melting hearth; melting the feed material in the melting hearth with a first heat source, thereby manufacturing a molten material; At least a portion is directly or indirectly transferred from the melting hearth to the atomizing hearth; a second heat source is used to heat the melting material in the atomizing hearth; at least a part of the melting material is from the atomizing hearth in a molten state Pass to an atomizing nozzle; and use the atomizing nozzle to form a droplet spray of the molten material, and then solidify at least a portion of the droplet spray to provide a metal powder material, wherein the composition of the metal powder material includes greater than 10 ppm of boron . A method for manufacturing a metal powder material, the method comprising: supplying a feed material to a melting hearth; melting the feed material in the melting hearth with a first heat source, thereby manufacturing a molten material; At least a portion is directly or indirectly transferred from the melting hearth to the atomizing hearth; a second heat source is used to heat the melting material in the atomizing hearth; at least a part of the melting material is from the atomizing hearth in a molten state Passing to the atomizing nozzle; and using the atomizing nozzle to form a droplet spray of the molten material, and then solidifying at least a portion of the droplet spray to provide a metal powder material, wherein the composition of the metal powder material includes about 4 by weight % Of vanadium, about 6% of aluminum and the rest are titanium and impurities. A metal powder material manufactured by the method of claim 1, wherein the metal powder material includes boron greater than 10 ppm.